Effect of Y, Sr, and Nd additions on the microstructure and microfracture mechanism of squeeze-cast AZ91-X magnesium alloys

This study aims to investigate the effects of Y, Sr, and Nd additions on the microstructure and microfracture mechanism of the four squeeze-cast magnesium alloys based on the commercial AZ91 alloy. Microstructural observation, in situ fracture tests, and fractographic observation were conducted on the alloys to clarify the microfracture process. Microstructural analyses indicated that grain refinement could be achieved by small additions of alloying elements, although the discontinuously precipitated Mg₁₇Al₁₂ phases still existed on grain boundaries. From in situ fracture observation of an AZ91-Sr alloy, it was seen that coarse needle-shaped compound particles and Mg₁₇Al₁₂ phases located on the grain boundary provided easy intergranular fracture sites under low stress intensity factor levels, resulting in the drop in toughness. On the other hand, the AZ91-Y and AZ91-Nd alloys showed improved fracture toughness, since deformation and fracture paths proceeded into grains rather than to grain boundaries, as the planar slip bands and twinnings actively developed inside the grains. These findings suggested, on the basis of the well-developed planar slip bands and twinnings, that the small addition of Y or Nd was very effective in improving fracture toughness.     

Effect of tungsten particle shape on dynamic deformation and fracture behavior of tungsten heavy alloys

The effect of the tungsten particle shape on the dynamic deformation and fracture behavior of tungsten heavy alloys was investigated. Dynamic torsional tests were conducted using a torsional Kolsky bar for five alloys, one of which was fabricated by the double-cycled sintering process, and then the test data were compared via microstructures, mechanical properties, adiabatic shear banding, and fracture mode. The dynamic torsional test results indicated that in the double-sintered tungsten alloy whose tungsten particles were very coarse and irregularly shaped, cleavage fracture occurred in the central area of the gage section with little shear deformation, whereas shear deformation was concentrated in the central area of the gage section in the other alloys. The deformation and fracture behavior of the double-sintered alloy correlated well with the observation of the impacted penetrator specimen and the in situ fracture test results, i.e., microcrack initiation at coarse tungsten particles and cleavage crack propagation through tungsten particles. These findings suggested that the cleavage fracture mode would be beneficial for the self-sharpening effect, and, thus, the improvement of the penetration performance of the double-sintered tungsten heavy alloy would be expected.     

Effect of tungsten particle shape on dynamic deformation and fracture behavior of tungsten heavy alloys

The effect of the tungsten particle shape on the dynamic deformation and fracture behavior of tungsten heavy alloys was investigated. Dynamic torsional tests were conducted using a torsional Kolsky bar for five alloys, one of which was fabricated by the double-cycled sintering process, and then the test data were compared via microstructures, mechanical properties, adiabatic shear banding, and fracture mode. The dynamic torsional test results indicated that in the double-sintered tungsten alloy whose tungsten particles were very coarse and irregularly shaped, cleavage fracture occurred in the central area of the gage section with little shear deformation, whereas shear deformation was concentrated in the central area of the gage section in the other alloys. The deformation and fracture behavior of the double-sintered alloy correlated well with the observation of the impacted penetrator specimen and the in situ fracture test results, i.e., microcrack initiation at coarse tungsten particles and cleavage crack propagation through tungsten particles. These findings suggested that the cleavage fracture mode would be beneficial for the self-sharpening effect, and, thus, the improvement of the penetration performance of the double-sintered tungsten heavy alloy would be expected.     

Effect of size and shape of tungsten particles on dynamic torsional properties in tungsten heavy alloys

The effect of the size and shape of tungsten particles on dynamic torsional properties in tungsten heavy alloys was investigated. Dynamic torsional tests were conducted on seven tungsten alloy specimens, four of which were fabricated by repeated sintering, using a torsional Kolsky bar, and then the test results were compared via microstructure, mechanical properties, adiabatic shear banding, and deformation and fracture mode. The size of tungsten particles and their hardness were increased as sintering temperature and time were increased, thereby deteriorating fracture toughness. The dynamic torsional test results indicated that in the specimens whose tungsten particles were coarse and irregularly shaped, cleavage fracture occurred predominantly with little shear deformation, whereas shear deformation was concentrated into the center of the gage section in the conventionally fabricated specimens. The deformation and fracture behavior of the specimens having coarse tungsten particles correlated well with the observation of the in situ fracture test results, i.e., cleavage crack initiation and propagation. These findings suggested that there would be an appropriate tungsten particle size because the cleavage fracture mode would be beneficial for the “self-sharpening” of the tungsten heavy alloys.     

<Emphasis Type="Italic">In-Situ</Emphasis> Fracture Observation and Fracture Toughness Analysis of Ni-Mn-Ga-Fe Ferromagnetic Shape Memory Alloys

The fracture property improvement of Ni-Mn-Ga-Fe ferromagnetic shape memory alloys containing ductile γ particles was explained by direct observation of microfracture processes using an in-situ loading stage installed inside a scanning electron microscope (SEM) chamber. The Ni-Mn-Ga-Fe alloys contained a considerable amount of γ particles in β grains after the homogenization treatment at 1073 K to 1373 K (800 °C to 1100 °C). With increasing homogenization temperature, γ particles were coarsened and distributed homogeneously along β grain boundaries as well as inside β grains. According to the in-situ microfracture observation, γ particles effectively acted as blocking sites of crack propagation and provided the stable crack growth, which could be confirmed by the R-curve analysis. The increase in fracture resistance with increasing crack length improved overall fracture properties of the Ni-Mn-Ga-Fe alloys. This improvement could be explained by mechanisms of blocking of crack propagation and crack blunting and bridging.     

Effects of be and fe content on plane strain fracture toughness in A357 alloys

The effect of Be and Fe content on the plane strain fracture toughnessK _IC of aluminum-based A357 alloys is investigated. The fracture behavior of A357 alloys has been evaluated as a function of both the magnitude and morphology of iron-bearing compounds and silicon particles. Addition of Be is beneficial for tensile properties and fracture toughness in the case of alloys containing intermediate (0.07 pct) and higher (0.15 pct) Fe levels. On the other hand, Be added to alloys containing the lower Fe (0.01 pct) level appears detrimental to tensile strength, but the quality index, notch-yield ratio (NYR), and plane strain fracture toughness were improved. Fractographic analysis reveals that crack extension of A357 alloys occurs mainly in an intergranular fracture mode. The fracture processes are initiated by void nucleation at iron-bearing compounds or irregularly shaped eutectic silicon particles as a result of their cracking and decohesion from the matrix. Then, void growth and coalescence result in growth of the main crack by shear-linkage-induced breakdown of submicronstrengthening particles. The effect of Be on increasingK _IC is more apparent in the higher Fe alloys than in the lower Fe alloys. Superior toughness obtained by microstructural control has also been achieved in the intermediate and higher Fe levels of Be-containing alloys, with values equal to those obtained in alloys of lower Fe content.     

A comparison study of microstructure and mechanical properties of Ti-24Al-14Nb-3V-0.5Mo with and without Si

A comparative study has been made of the room- and elevated-temperature properties, room-temperature fracture toughness, fatigue-crack propagation rates, and 650 °C creep properties of Ti-24Al-14Nb-3V-0.5Mo with and without 0.9 at. pct Si. Both alloys have microstructures consisting of the α ₂, B2, and the orthorhombic O phase, with different proportions of the α ₂ phase relative to the (O + B2) mixtures, depending on solution-treatment temperature. The alloy with a Si addition contains additional primary ζ-Ti₅Si₃ particles distributed in the (O + B2) matrix. Tests of mechanical properties showed that the incorporation of a small fraction (about 0.03 by volume) of the Ti₅Si₃ phase leads to greater room-temperature and elevated-temperature strengths, but lower room-temperature elongations and fracture toughness as compared with the base alloy. Alloys containing greater volume fractions of the α ₂ phase exhibited better tensile ductility, and this was attributed to the concurrent stabilization of the B2 phase. Examination of tensile-tested and fatigued specimens indicates that the primary failure mode of the alloys, regardless of Si addition, was due to the brittleness of the α ₂ phase; the silicide particles that debonded from the matrix also contribute to cracking in the monotonic loading mode. Up to a 20 pct improvement in creep-rupture life was observed in the Si-containing alloys, and this was interpreted in terms of the solute-strengthening effect of Si. While the incorporated Ti₅Si₃ phase has an unfavorable effect on ductility and room-temperature fracture toughness, the difference in fatigue-crack propagation rates between the alloys with and without Si is minimal. It is concluded that the controlling factor for the fatigue failure in orthorhombic alloys is related to the (α ₂ + O + B2) microstructure, instead of the Ti₅Si₃ particles.     

Microstructure and mechanical behavior of Cr-Cr2Hfin situ intermetallic composites

A detailed investigation of the effects of microstructural changes on the mechanical behavior of twoin situ intermetallic composites with Cr and Cr₂Hf phases in the Cr-Hf system was performed. The nominal compositions (at. pct) of the alloys were Cr-5.6Hf (hypoeutectic) and Cr-13Hf (eutectic). The study included evaluations of strength, ductility, and fracture toughness as a function of temperature and creep behavior. Two microstructures in each alloy were obtained by heat treatments at 1250 ‡C (fine microstructure) and 1500 ‡C (coarse microstructure). A decrease in elastic strength (stress at the onset of inelastic response in the load-deflection curve) with the coarsening of the microstructures was noted for both alloys below 1000 ‡C. The Cr-13Hf alloy retained strength to a higher test temperature, relative to Cr-5.6Hf alloy, under both microstructural conditions. The alloys showed no evidence of ductility at room temperature. However, in the coarse microstructure of the Cr-5.6Hf alloy, the primary Cr exhibited ductility at and above 200 ‡C; ductility in primary Cr could be seen only at and above 1000 ‡C for the fine microstructure. In other words, the temperature at which ductility was first observed decreased from about 1000 ‡C to about 200 ‡C due to high-temperature heat treatment in this alloy. Both microstructures of Cr-5.6Hf alloy showed a significant increase in fracture toughness with increasing test temperature. However, the increases in fracture toughness with temperature for the Cr-13Hf alloy microstructures were relatively small. Both alloys showed about four orders of magnitude reduction in steady-state creep rates relative to pure Cr at 1200 ‡C. The results are analyzed in the light of deformation characteristics and fracture micromechanisms. The effects of microstructural factors, such as the size and continuity of phases, solubility levels of Hf as well as interstitial elements in Cr, on the observed mechanical behavior are discussed. Formerly Research Scientist, Materials and Processes, UES, Inc.     

The effect of deformation-induced transformation on the fracture toughness of commercial titanium alloys

The effect of deformation-induced transformation of metastableβ phase on the ductility and toughness of four commercial titanium alloys was investigated. Tensile tests, Charpy impact tests, and both static and dynamic fracture toughness tests were carried out at temperatures between 77 and 473 K on four titanium alloys containing metastableβ phase. Deformation-inducedα″ (orthorhombic martensite) was observed in an (α + β)-type Ti-6Al-2Sn-4Zr-6Mo alloy. The dynamic fracture toughness of this alloy increased considerably at 223 K compared to those at other temperatures. In another (α + β)-type Ti-6A1-4V alloy, the static fracture toughness at 123 K and the dynamic fracture toughness at 223 K were increased considerably by the presence of deformation-induced martensite compared to those at other temperatures. The strength increased as the temperature decreased in this alloy. An abnormal elongation of aβ-type alloy, Ti-15V-3Al-3Sn-3Cr, at 123 K was attributed to the mechanical twinning of theβ phase. However, the effect of deformation-induced transformation on the fracture toughness of Ti-3Al-8V-6Cr-4Mo-4Zr alloy was not observed. Formerly Visiting Associate Professor, Department of Metallurgical Engineering and Materials Science, Carnegie Mellon University, Pittsburgh, PA. Formerly with the Department of Production Systems Engineering, Toyohashi University of Technology.     

Toughness-strength relations in the overaged 7449 al-based alloy

This article examines the relationship between plane strain fracture toughness, K _Ic , the tensile properties, and the microstructure of the overaged 7449 aluminum-plate alloy, and compares them to the 7150 alloy. The 7449 alloy has a higher content of η′/η precipitates; and, the 7150 alloy contains a greater amount of coarse intermetallic particles, as it contains an appreciable amount of coarse S phase (Al₂CuMg), which is largely absent in the 7449 alloy. The toughness of the alloys shows an increase on overaging, and the 7449 alloy shows a reasonably linear toughness—yield strength relation on extended overaging. Several mechanisms of failure occur: coarse voiding at intermetallics and a combined intergranular/transgranular shear fracture mode, with the former becoming more important as overaging progresses. Drawbacks of existing models for toughness are discussed, and a new model for plane strain fracture toughness, based on the microstructurally dependent work-hardening factor, K _A , introduced in Ashby’s theory of work hardening, is developed. This model predicts a linear relation between K _Ic and K _A ^/0.85 /σ _ys ^/0.35 , where σ _ys is the yield strength, which is consistent with the experimental data.     

The influences of multiscale-sized second-phase particles on ductility of aged aluminum alloys

Commercially aged aluminum alloys commonly contain second-phase particles of three class sizes, and all contribute appreciably to the mechanical properties observed at the macroscopic scale. In this article, a multiscale model was constructed to describe the individual and coupling influences of the three types of second-phase particles on tensile ductility. The nonlinear relationships between the parameters of particles, including volume fraction, size, aspect ratio, shape, and ductility, were then quantitatively established and experimentally validated by the measured results from disc-shaped precipitate containing Al-Cu-Mg alloys and needle-shaped precipitate containing Al-Mg-Si alloys, as well as by using other researchers’ previously published results. In addition, we discuss extending this model to predict the fracture toughness of aluminum alloys.     

Comparison of the Effect of Individual and Combined Zr and Mn Additions on the Fracture Behavior of Al-Cu-Li Alloy AA2198 Rolled Sheet

The effect of individual and combined addition of dispersoid-forming alloying elements Zr and Mn on the fracture behavior of the Al-Cu-Li alloy 2198 has been investigated by the Kahn tear test. Overall, the standard baseline 2198 alloy containing only Zr exhibited the best performance, while the alloy with the combined presence of Zr and Mn was slightly inferior. The lowest properties were seen for a Zr-free 2198-0.4Mn alloy variant. In the T351 temper fracture initiated at coarse constituent particles that formed large cavities and microvoid sheets linked the initial sites of void growth. In the Mn-containing alloys microvoids clearly nucleated at the coarser Al₂₀Cu₂Mn₃ dispersoids within the microstructure, while this was not identifiable for the finer coherent Al₃Zr dispersoids. However, this difference in the mechanism of cavity linkage had little effect on the overall toughness of the materials, which was more closely related to the effect of Mn and Zr on the level of recrystallization. Extended artificial aging promoted grain boundary decohesion due to the precipitation of high densities of T₁ particles on GBs and favored a cleavage fracture mode. Particle decohesive fracture was also promoted by T₁ precipitation on the Mn dispersoids.     

Granular product in a high strength,low alloy containing molybdenum and niobium

The formation and microstructure of the granular product and its effect on the mechanical properties of a high-strength, low alloy steel containing molybdenum and niobium have been investigated. It was found that the granular product “islands” are composed of both twinned martensite and dislocated martensite. The effect of the granular “islands” on the strength at room temperature and at 400 °C has been determined. The results showed that the strength increased and both the impact and fracture toughness decreased as the volume fraction of granular “islands” was increased.In situ fracture studies indicated that the three stages of the microfracture process of the specimen containing granular “islands” are the initiation of voids at interfaces between the granular “islands” and the bainitic ferrite matrix, followed by void growth and finally, coalescence by shear.     

Improving the fracture toughness of constituent phases and Nb-based <Emphasis Type="Italic">in-situ</Emphasis> composites by a computational alloy design approach

A computational alloy design approach has been used to identify a ductile matrix for Nb-based in-situ composites containing Ti, Hf, Cr, Si, and Ge additions. Candidate alloys in the form of cast buttons were fabricated by arc melting. Coupon specimens were prepared and heated treated to vary the microstructure. Backscattered electron (BSE) microscopy, quantitative metallography, energy-dispersive spectroscopy (EDS), and X-ray diffraction (XRD) were utilized to characterize the morphology, volume fraction, composition, and crystallography of individual phases in the microstructure. The fracture toughness of the composites was characterized by three-point bending and compact-tension techniques, while the fracture toughness of individual phases in the in-situ composites was determined by an indentation technique. The composition, crystallography, and volume fraction of individual phases were correlated with the fracture-toughness results to assess (1) the role of constituent properties in the overall fracture resistance of the composites and (2) the effectiveness of the computational design approach. The results indicated that the effects of alloy addition and plastic constraint on fracture toughness were reasonably predicted, but the conditions for relaxing plastic constraint to attain higher fracture toughness were not achieved.     

Fracture in equiaxed two phase alloys: part ii. fracture in alloys with isolated plastic particles

A model, describing fracture of two phase equiaxed alloys containing isolated plastic particles within an elastically deforming matrix, has been developed. The model relates fracture toughness parameters to the microstructure and mechanical characteristics of the individual phases. The model utilizes the concepts of a process zone and crack closing forces in the process zone along with recent developments in the fracture mechanics of toughened ceramics. One adjustable parameter, either the extent of the process zone or the effective “gauge length” of plastic particles within the process zone, is used in the analysis. The values of these parameters, as deduced from experimental fracture mechanics studies in Co-CoAl alloys, are reasonable in their magnitude and depend on alloy microstructure in the manner predicted from the analysis. M. A. PRZYSTUPA, formerly Graduate Research Assistant, Department of Metallurgical Engineering, Michigan Technological University     

The effect of consolidation temperature on microstructure and mechanical properties in powder metallurgy-processed 2XXX aluminum alloy composites reinforced with SiC particulates

The effects of consolidation temperature on the development of microstructure and resulting mechanical properties of 2XXX aluminum composites were studied in an effort to fabricate composites with enhanced properties. Type 2009 and 2124 aluminum composites reinforced with 15 pct SiC particulates were produced at four different consolidation temperatures, i.e., 560 °C, 580 °C, 600 °C, and 620 °C, followed by extrusion at 450 °C. The 2124 Al-SiC _p composites consolidated at 560 °C showed the most homogeneous and the finest microstructures with the best mechanical properties, which were even better than the whisker-reinforced counterparts. All the results of the tensile tests, hardness tests, in situ scanning electron microscope (SEM) observations of the fracture process, and the apparent fracture toughness indicated that the prominent mechanical property improvement observed in the 2124 Al-SiC _p was associated largely with the reduction of volume fraction of the detrimental coarse and brittle manganese-containing particles, as well as grain refinement. The detrimental manganese-containing particles that were routinely observed in the 2124 Al-SiC composites were very effectively refined by the reduction of consolidation temperature, and they rather contributed to the overall mechanical properties of the composites through Orowan-type strengthening and grain growth inhibition.     

A study of fracture in high purity 7075 aluminum alloys

Ten different alloys based on the 7075 composition were used to study the effect of purity level, dispersoid type, and heat treatment on fracture toughness. Five purity levels ranging from 0.03 to 0.30 wt pct Fe + Si and two dispersoid types were investigated. Each alloy was given two heat treatments: the standard T651 heat treatment or a special thermomechanical treatment (TMT). Fracture toughness was measured using notched round tensile specimens taken from both the longitudinal and long-transverse directions. The notched round tensile test was modified to give the “plastic energy per unit area”. This fracture toughness parameter gave the same ranking for corresponding alloy/heat treatment combinations as the total energy per unit area measured on precracked Charpy specimens. The fracture toughness ranking for the ten alloys was the same in the longitudinal and long-transverse directions. This suggests the elongated distribution of constituent particles in the rolling direction does not change the failure mechanism. Fractographic evidence showed a bimodal distribution of ductile dimple size in all ten alloys. The number of large ductile dimples decreased with increasing purity level while the number of small ductile dimples increased. This is interpreted to mean that the smaller dispersoid and hardening particles become increasingly important in controlling the fracture toughness as the large intermetallic particles are eliminated by increasing the purity of these aluminum alloys. Since thermomechanical processing controls the amount and type of these smaller particles, it is a useful means for increasing fracture toughness in high purity aluminum alloys.     

Electrochemical behavior of Ca-based bulk metallic glasses

Since 2002, numerous Ca-based bulk metallic glass (BMG) alloys have been discovered. These BMG alloys are of interest because of their low densities and costs; however, few studies have examined the properties of these novel materials. In this study, the thermophysical and electrochemical behavior of three Ca-based BMGs was examined and compared to a crystalline, Mg-based alloy. Cyclic-anodic polarization tests were conducted in a 0.05 M Na₂SO₄ electrolyte, and posttest analyses by scanning electron microscopy were conducted to assess the damage to the exposed surfaces.     

Ultrafine high-cobalt hard alloys. II. Connection between mechanical properties and structure

The experimental dependences of strength, plastic properties, hardness, and fracture toughness on sintering or pressing temperature for ultrafine alloy WC-41 wt.% Co are presented. The alloy densifies in solid phase and temperature varies from 950 to 1250°C. The dependences of mechanical properties are extreme, excepting fracture toughness. The properties reach their maximum values at 1050 to 1150°C depending on the type of testing. Fracture toughness continuously increases with densification temperature. The highest values of some properties are reached after additional solid-phase annealing. The mechanical properties of ultrafine high-cobalt alloy samples are assessed with the use of structural parameters and empirical equations established for standard hard WC-Co alloys sintered in liquid phase. The calculated and experimental values of properties differ: transverse rupture strength, fracture toughness, and yield strength show higher values, while hardness and compressive strength have lower values as compared with calculated ones.     

Effect of TiN particles and microstructure on fracture toughness in simulated heat-affected zones of a structural steel

Thermally stable TiN particles can effectively pin austenite grain boundaries in weld heat-affected zones (HAZs), thereby improving toughness, but can also act as cleavage initiators. The HAZs simulated in a GLEEBLE 1500 TCS using two peak temperatures (T _p ) and three cooling times (Δ∼ _8/5) have determined the effects of matrix microstructure and TiN particle distribution on the fracture toughness (crack tip opening displacement (CTOD)) of three steels microalloyed with 0.006, 0.045, and 0.1 wt pct Ti. Coarse TiN (0.5 to 6 μm) particles are identified in steels with the two higher levels of Ti, and fine Ti(C, N) (35 to 500 nm) particles were present in all three steels. Large prior austenite grain size caused by higher T _p decreased fracture toughness considerably in steels containing coarse TiN particles but had little effect in their absence. Fracture toughness was largely independent of matrix microstructure in the presence of coarse particles. Cleavage fracture initiation was observed to occur at coarse TiN particles in the samples with a large prior austenite grain size. Alloy thermodynamics have been used to rationalize the influence of Ti content on TiN formation and its size.